Modeling approaches and software for predicting the performance of milling operations at MAL-UBC

The author has been conducting research in the area of metal cutting mechanics, metal cutting dynamics, machine tool vibrations, precision machining and machine tool control in his Manufacturing Automation Laboratory, at The University of British Columbia, Canada since 1986. This article summarizes the research conducted in mechanics and dynamics of metal cutting in our laboratory. Modeling of mechanics of metal cutting is summarized first. The models include orthogonal to oblique cutting transformation, mechanistic modeling of cutting coefficients, slip line field and Finite Element modeling. The author mostly focused on milling. The kinematics of milling with and without structural vibrations is modeled. The geometric model of end mills and inserted cutters with arbitrary geometry are modeled. The prediction of forces, torque, power and dimensional surface finish is explained for milling operations. The chatter stability for milling operations is presented. The metal cutting knowledge is transferred to manufacturing industry by combining all the models in shop friendly software.